Compositions containing derivatized polyamines

ABSTRACT

Disclosed herein are aqueous coating compositions containing an anionically stabilized polymer, one or more derivatized polyamines, and a volatile base. Coating compositions can further include one or more additional copolymers, which may or may not be anionically stabilized, and/or additional additives, including pigments, defoamers, pigment dispersing agents, thickeners, surfactants, and combinations thereof. By incorporating a derivatized polyamine, such as an alkoxylated polyamine, the setting time of the coating compositions can be decreased. Also provided are coatings formed from the coating compositions described herein, as well as methods of forming these coatings.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/714,497 filed Oct. 16, 2012, the disclosure of which are herebyincorporated by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to coating compositionscontaining derivatized polyamines for use in a variety of applications.

BACKGROUND

The formation of durable, high quality coatings on exterior surfacesposes numerous challenges. Notably, coatings on exterior surfacestypically remain exposed to the elements during application and drying.As a result, weather conditions during coating application and dryingcan impact the quality of exterior coatings. In particular, rainfallduring and/or after coating applications can wash-off some or all of thecoating, resulting in coating failure.

By shortening the setting time of coatings, instances of coatingfailure, such as those due to unanticipated rainfall, can be minimizedTowards this end, additives have been incorporated into coatings todecrease setting time. While coatings containing setting additives doexhibit quick-setting behavior, these coatings suffer from seriousdrawbacks, including decreased elongation at break and significantyellowing upon weathering. As a result, existing quick-settings coatingshave proved unsuitable for many applications.

SUMMARY OF THE DISCLOSURE

Disclosed are quick-setting aqueous coating compositions comprising ananionically stabilized copolymer, a derivatized polyamine, and avolatile base. The coatings exhibit quick setting times upon applicationto a surface. In addition, the coating compositions are substantiallynon-yellowing upon weathering, and display suitable physical properties,including sufficient elongation at break, for a wide variety of exteriorapplications.

The coating compositions contain one or more anionically stabilizedpolymers. The anionically stabilized polymers can be derived from one ormore ethylenically-unsaturated monomers, including (meth)acrylatemonomers, vinyl aromatic monomers, ethylenically unsaturated aliphaticmonomers, vinyl ester monomers, and combinations thereof. In someembodiments, the anionically stabilized copolymer has a measured T_(g)of between −70° C. and 25° C.

In some instances, the anionically stabilized copolymer is anacrylic-based copolymer that can be derived from: (i) one or more(meth)acrylate monomers; (ii) one or more carboxylic acid-containingmonomers; (iii) optionally one or more acetoacetoxy monomers; (iv)optionally one or more phosphorus-containing monomers; and (v)optionally one or more additional ethylenically-unsaturated monomers,excluding monomers (i), (ii), (iii), and (iv). In certain embodiments,the anionically stabilized copolymer is derived from greater than 80% byweight of one or more (meth)acrylate monomers, such as methylmethacrylate, butyl acrylate, 2-ethylhexylacrylate, and combinationsthereof. In some embodiments, the anionically stabilized copolymer isderived from greater than 0% by weight to 5% by weight of one or morecarboxylic acid-containing monomers, such as acrylic acid, methacrylicacid, itaconic acid, maleic acid, fumaric acid, and combinationsthereof. In certain embodiments, the anionically stabilized copolymer isderived from greater than 0% by weight to 35% by weight of one or moreadditional ethylenically-unsaturated monomers, such as styrene,acrylamide, and combinations thereof.

The coating compositions also contain a derivatized polyamine, such as aderivatized polyalkyleneimine, a derivatized polyvinylamine, or acombination thereof. Exemplary derivatized polyamines includealkoxylated polyamines derived from ethylene oxide, propylene oxide,butylene oxide, and combinations thereof.

Suitable derivatized polyamines can possess a variety of molecularweights and degrees of nitrogen-derivatization. For example, thederivatized polyamine can have an average molecular weight of between5,000 and 5,000,000 Daltons and/or a degree of nitrogen-derivatizationbetween 5% and 100%. In some embodiments, the derivatized polyamine ispresent in the coating composition at between 0.1% by weight and 5% byweight, based on the dry weight of the anionically stabilized copolymer.

The coating compositions also contain a volatile base. Exemplaryvolatile bases include, but are not limited to, ammonia, loweralkylamines such as dimethylamine and diethylamine, ethanolamine,morpholine, aminopropanol, 2-amino-2-methyl-1-propanol,2-dimethylaminoethanol, and combinations thereof. In certainembodiments, the volatile base is ammonia.

Coating compositions can further contain an additional polymer. Theadditional polymer can be, for example, a polymer or copolymer derivedfrom one or more (meth)acrylate monomers, vinyl aromatic monomers,ethylenically unsaturated aliphatic monomers, vinyl ester monomers, andcombinations thereof. The coating compositions can also include one ormore additives, including pigments, fillers, dispersants, coalescents,pH neutralizing agents, plasticizers, defoamers, surfactants,thickeners, biocides, co-solvents, and combinations thereof.

Also provided are coatings formed from the coating compositionsdescribed herein, as well as methods of forming these coatings.Generally, coatings are formed by applying a coating compositiondescribed herein to a surface, and allowing the coating to dry to form acoating. The resultant dry coatings typically comprise, at minimum, ananionically stabilized polymer and a derivatized polyamine. The drycoatings can further comprise one or more additional polymers and/oradditives as described above. The coating thickness can vary dependingupon the application of the coating. In some embodiments, the coatinghas a dry thickness of between 10 mils and 100 mils. In certainembodiments, the coating has a tensile strength of greater than 200 psiafter a drying period of 14 days at room temperature, according to ASTMD-2370, and/or an elongation at break of greater than 100% after adrying period of 14 days at room temperature, according to ASTM D-2370.In some embodiments, the coating has a tensile strength of greater than200 psi, and an elongation at break of greater than 100%, according toASTM D-2370, after 1,000 hours of accelerated weathering.

The coating compositions can be applied to a variety of surfacesincluding, but not limited to metal, asphalt, concrete, stone, ceramic,wood, plastic, polymer, polyurethane foam, glass, and combinationsthereof. The coating compositions can be applied to interior or exteriorsurfaces. In certain embodiments, the surface is an architecturalsurface, such as a roof, wall, floor, or combination thereof.

The details of one or more embodiments are set forth in the descriptionbelow. Other features, objects, and advantages will be apparent from thedescription and from the claims.

DETAILED DESCRIPTION

As used herein, the term “(meth)acrylate monomer” includes acrylate,methacrylate, diacrylate, and dimethacrylate monomers.

The coating compositions described herein contain one or moreanionically stabilized polymers. Suitable anionically stabilizedpolymers include copolymers derived from one or moreethylenically-unsaturated monomers. Exemplary ethylenically-unsaturatedmonomers include (meth)acrylate monomers, vinyl aromatic monomers (e.g.,styrene), ethylenically unsaturated aliphatic monomers (e.g.,butadiene), vinyl ester monomers (e.g., vinyl acetate), and combinationsthereof. In some embodiments, the anionically stabilized polymers caninclude pure acrylic copolymers, styrene acrylic copolymers, vinylacrylic copolymers, or carboxylated or non-carboxylated styrenebutadiene copolymers.

In some embodiments, the anionically stabilized polymer includes anacrylic-based copolymer. Acrylic-based copolymers include copolymersderived from one or more (meth)acrylate monomers. The acrylic-basedcopolymer can be a pure acrylic polymer (i.e., a polymer or copolymerderived exclusively from (meth)acrylate monomers), a styrene-acrylicpolymer (i.e., a copolymer derived from styrene and one or more(meth)acrylate monomers), or a vinyl-acrylic polymer (i.e., a copolymerderived from one or more vinyl ester monomers and one or more(meth)acrylate monomers).

In some instances, the acrylic-based copolymer includes:

(i) one or more (meth)acrylate monomers;

(ii) one or more carboxylic acid-containing monomers;

(iii) optionally one or more acetoacetoxy monomers;

(iv) optionally one or more phosphorus-containing monomers; and

(v) optionally one or more additional ethylenically-unsaturatedmonomers, excluding monomers (i), (ii), (iii), and (iv).

The acrylic-based copolymer can be derived from greater than 55% byweight or greater of one or more (meth)acrylate monomers (e.g., 65% byweight or greater, 75% by weight or greater, 80% by weight or greater,85% by weight or greater, 88% by weight or greater, 90% by weight orgreater, 91% by weight or greater, 92% by weight or greater, 93% byweight or greater, 94% by weight or greater, or 95% by weight or greaterof the (meth)acrylate monomer) based on the total weight of monomers. Insome embodiments, the (meth)acrylate monomer can include esters ofα,(β-monoethylenically unsaturated monocarboxylic and dicarboxylic acidshaving 3 to 6 carbon atoms with alkanols having 1 to 12 carbon atoms(e.g., esters of acrylic acid, methacrylic acid, maleic acid, fumaricacid, or itaconic acid, with C₁-C₂₀, C₁-C₁₂, C₁-C₈, or C₁-C₄ alkanols).

Exemplary acrylate and (meth)acrylate monomers include, but are notlimited to, methyl acrylate, methyl (meth)acrylate, ethyl acrylate,ethyl (meth)acrylate, butyl acrylate, butyl (meth)acrylate, isobutyl(meth)acrylate, n-hexyl (meth)acrylate, ethylhexyl (meth)acrylate,n-heptyl (meth)acrylate, ethyl (meth)acrylate, 2-methylheptyl(meth)acrylate, octyl (meth)acrylate, isooctyl (meth)acrylate, n-nonyl(meth)acrylate, isononyl (meth)acrylate, n-decyl (meth)acrylate,isodecyl (meth)acrylate, dodecyl (meth)acrylate, lauryl (meth)acrylate,tridecyl (meth)acrylate, stearyl (meth)acrylate, glycidyl(meth)acrylate, alkyl crotonates, vinyl acetate, di-n-butyl maleate,di-octylmaleate, acetoacetoxyethyl (meth)acrylate, acetoacetoxypropyl(meth)acrylate, hydroxyethyl (meth)acrylate, allyl (meth)acrylate,tetrahydrofurfuryl (meth)acrylate, cyclohexyl (meth)acrylate,2-ethoxyethyl (meth)acrylate, 2-methoxy (meth)acrylate,2-(2-ethoxyethoxy)ethyl (meth)acrylate, 2-ethylhexyl (meth)acrylate,2-propylheptyl (meth)acrylate, 2-phenoxyethyl (meth)acrylate, isobornyl(meth)acrylate, caprolactone (meth)acrylate, polypropyleneglycolmono(meth)acrylate, polyethyleneglycol (meth)acrylate, benzyl(meth)acrylate, 2,3-di(acetoacetoxy)propyl (meth)acrylate, hydroxypropyl(meth)acrylate, methylpolyglycol (meth)acrylate,3,4-epoxycyclohexylmethyl (meth)acrylate, 1,6 hexanedioldi(meth)acrylate, 1,4 butanediol di(meth)acrylate and combinationsthereof.

In certain instances, the acrylic-based copolymer is derived from two ormore, three or more, or four or more (meth)acrylate monomers. In certainembodiments, the acrylic-based copolymer is derived from at least two(meth)acrylate monomers, wherein at least one of the (meth)acrylatemonomers has a T_(g) for its corresponding homopolymer of 80° C. orgreater (e.g., 90° C. or greater, 100° C. or greater, or 105° C. orgreater) (e.g., methyl methacrylate) and at least one of the(meth)acrylate monomers has a T_(g) for its corresponding homopolymer of0° C. or less (e.g., −10° C. or less, −20° C. or less, −30° C. or less,−40° C. or less, or −50° C. or less) (e.g., butyl acrylate and/or2-ethyl hexyl acrylate).

In particular embodiments, the acrylic-based copolymer is derived fromone or more (meth)acrylate monomers selected from the group consistingof methyl methacrylate, butyl acrylate, 2-ethylhexylacrylate, andcombinations thereof.

The acrylic-based copolymer can be derived from greater than 0% byweight to 5% by weight of one or more carboxylic acid-containingmonomers based on the total weight of monomers. Exemplarycarboxylic-acid monomers include, but are not limited to,α,β-monoethylenically unsaturated mono- and dicarboxylic acids, such asacrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleicacid, fumaric acid, dimethacrylic acid, ethylacrylic acid, allylaceticacid, vinylacetic acid, mesaconic acid, methylenemalonic acid,citraconic acid, and combinations thereof. In certain embodiments, theacrylic-based copolymer is derived from greater than 0% by weight to 5%by weight, or greater than 0% by weight to 2.5% by weight, acrylic acid,methacrylic acid, or combinations thereof.

The acrylic-based copolymer can be derived from greater than 0% byweight to 5% by weight of one or more phosphorus-containing monomers.Examples of suitable phosphorus-containing monomers include dihydrogenphosphate esters of alcohols in which the alcohol contains apolymerizable vinyl or olefenic group, allyl phosphate,phosphoalkyl(meth)acrylates such as 2-phosphoethyl(meth)acrylate (PEM),2-phosphopropyl(meth)acrylate, 3-phosphopropyl (meth)acrylate, andphosphobutyl(meth)acrylate, 3-phospho-2-hydroxypropyl(meth)acrylate,mono- or di-phosphates of bis(hydroxymethyl) fumarate or itaconate;phosphates of hydroxyalkyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate,3-hydroxypropyl(meth)acrylate, ethylene oxide condensates of(meth)acrylates, H₂C═C(CH₃)COO(CH₂CH₂O)_(n)P(O)(OH)₂, and analogouspropylene and butylene oxide condensates, where n is an amount of 1 to50, phosphoalkyl crotonates, phosphoalkyl maleates, phosphoalkylfumarates, phosphodialkyl (meth)acrylates, phosphodialkyl crotonates,vinyl phosphonic acid, allyl phosphonic acid,2-acrylamido-2methylpropanephosphinic acid, α-phosphonostyrene,2-methylacrylamido-2-methylpropanephosphinic acid,(hydroxy)phosphinylalkyl(meth)acrylates, (hydroxy)phosphinylmethylmethacrylate, and combinations thereof. In certain embodiments, theacrylic-based copolymer is derived from greater than 0% by weight to2.5% by weight of one or more phosphorus-containing monomers. Inparticular embodiments, the acrylic-based copolymer is derived fromgreater than 0% by weight to 5% by weight, or greater than 0% by weightto 3% by weight 2-phosphoethyl methacrylate (PEM).

The acrylic-based copolymer can be derived from greater than 0% byweight to 5% by weight of one or more acetoacetoxy monomers. Suitableacetoacetoxy monomers include acetoacetoxyalkyl (meth)acrylates, such asacetoacetoxyethyl (meth)acrylate (AAEM), acetoacetoxypropyl(meth)acrylate, acetoacetoxybutyl (meth)acrylate, and2,3-di(acetoacetoxy)propyl (meth)acrylate; allyl acetoacetate; vinylacetoacetate; and combinations thereof. In certain embodiments, theacrylic-based copolymer is derived from greater than 0% to 10% or from0.5% to 5% by weight of one or more acetoacetoxy monomers.

The acrylic-based copolymer can be derived from greater than 0% byweight to 35% by weight of one or more additionalethylenically-unsaturated monomers. For example, the acrylic-basedcopolymer can further include a vinyl aromatic having up to 20 carbonatoms, a vinyl ester of a carboxylic acid comprising up to 20 carbonatoms, a (meth)acrylonitrile, a vinyl halide, a vinyl ether of analcohol comprising 1 to 10 carbon atoms, an aliphatic hydrocarbon having2 to 8 carbon atoms and one or two double bonds, a silane-containingmonomer, a (meth)acrylamide, a (meth)acrylamide derivative, asulfur-based monomer, or a combination of these monomers.

Suitable vinyl aromatic compounds include styrene, α- andp-methylstyrene, α-butylstyrene, 4-n-butylstyrene, 4-n-decylstyrene,vinyltoluene, and combinations thereof. Vinyl esters of carboxylic acidshaving comprising up to 20 carbon atoms include, for example, vinyllaurate, vinyl stearate, vinyl propionate, versatic acid vinyl esters,vinyl acetate, and combinations thereof. The vinyl halides can includeethylenically unsaturated compounds substituted by chlorine, fluorine orbromine, such as vinyl chloride and vinylidene chloride. The vinylethers can include, for example, vinyl ethers of alcohols comprising 1to 4 carbon atoms, such as vinyl methyl ether or vinyl isobutyl ether.Aliphatic hydrocarbons having 2 to 8 carbon atoms and one or two doublebonds can include, for example, hydrocarbons having 4 to 8 carbon atomsand two olefinic double bonds, such as butadiene, isoprene, andchloroprene. Silane containing monomers can include, for example, vinylsilanes, such as vinyltrimethoxysilane, vinyltriethoxysilane (VTEO),vinyl tris(2-methoxyethoxysilane), and vinyl triisopropoxysilane, and(meth)acrylatoalkoxysilanes, such as(meth)acryloyloxypropyltrimethoxysilane,γ-(meth)acryloxypropyltrimethoxysilane, andγ-(meth)acryloxypropyltriethoxysilane. (Meth)acrylamide derivativesinclude, for example, keto-containing amide functional monomers definedby the general structure belowCH₂═CR₁C(O)NR₂C(O)R₃wherein R₁ is hydrogen or methyl; R₂ is hydrogen, a C₁-C₄ alkyl group,or a phenyl group; and R₃ is hydrogen, a C₁-C₄ alkyl group, or a phenylgroup. For example, the (meth)acrylamide derivative can be diacetoneacrylamide (DAAM) or diacetone methacrylamide. Sulfur-containingmonomers include, for example, sulfonic acids and sulfonates, such asvinylsulfonic acid, 2-sulfoethyl methacrylate, sodium styrenesulfonate,2-sulfoxyethyl methacrylate, vinyl butylsulfonate, sulfones such asvinylsulfone, sulfoxides such as vinylsulfoxide, and sulfides such as1-(2-hydroxyethylthio) butadiene. When present, the sulfur-containingmonomers are generally present in an amount greater than 0% by weight to5% by weight.

In some cases, the coating composition comprises an acrylic-basedcopolymer derived from:

(i) 10-15% by weight methyl methacrylate;

(ii) 50-70% by weight butyl acrylate;

(iii) 15-30% by weight 2-ethylhexylacrylate;

(iv) greater than 0 to 5% by weight carboxylic acid-containing monomers;

(v) 0-5% by weight acrylamide;

(vi) 0-5% by weight acetoacetoxy monomers; and

(vii) 0-5% by weight phosphorus-containing monomers.

In some cases, the coating composition comprises an acrylic-basedcopolymer derived from:

(i) 55-75% by weight butyl acrylate;

(ii) 0-25% by weight 2-ethylhexylacrylate;

(iii) 10-35% by weight styrene;

(iv) greater than 0 to 5% by weight carboxylic acid-containing monomers;

(v) 0-5% by weight acrylamide;

(vi) 0-5% by weight acetoacetoxy monomers; and

(vii) 0-5% by weight phosphorus-containing monomers.

In some embodiments, the anionically stabilized polymer includes astyrene-butadiene copolymer. The styrene-butadiene copolymer can becarboxylated (i.e., further derived from one or more carboxylicacid-containing monomers) or can be non-carboxylated.

The anionically stabilized polymer can have a glass-transitiontemperature (T_(g)), as measured by differential scanning calorimetry(DSC) using the mid-point temperature using as described, for example,in ASTM 3418/82, of between −70° C. and 25° C. In certain instances, theanionically stabilized copolymer has a measured T_(g) of greater than−70° C. (e.g., greater than −60° C., greater than −50° C., greater than−40° C., greater than −30° C., greater than −20° C., greater than −10°C., or greater than 0° C.). In some cases, the anionically stabilizedcopolymer has a measured T_(g) of less than 15° C. (e.g., less than 10°C., less than 0° C., less than −10° C., less than −20° C., less than−30° C., less than −40° C., less than −50° C., or less than −60° C.). Incertain embodiments, the anionically stabilized copolymer has a measuredT_(g) of between −60° C. and 15° C., −55° C. and 10° C., or −50° C. and0° C. In some embodiments, the anionically stabilized polymer can have aT_(g) of from 25° C. to 80° C. In these embodiments, the coatingcomposition can further comprise a coalescing agent suitable to depressthe T_(g) of the anionically stabilized polymer into the film formingrange.

The anionically stabilized polymer can be prepared by heterophasepolymerization techniques, including, for example, free-radical emulsionpolymerization, suspension polymerization, and mini-emulsionpolymerization. In some examples, the anionically stabilized polymer isprepared by polymerizing the monomers using free-radical emulsionpolymerization. The emulsion polymerization temperature can range from10° C. to 130° C. or from 50° C. to 90° C. The polymerization medium caninclude water alone or a mixture of water and water-miscible liquids,such as methanol, ethanol or tetrahydrofuran. In some embodiments, thepolymerization medium is free of organic solvents and includes onlywater.

The emulsion polymerization can be carried out as a batch process, as asemi-batch process, or in the form of a continuous process. In someembodiments, a portion of the monomers can be heated to thepolymerization temperature and partially polymerized, and the remainderof the monomer batch can be subsequently fed to the polymerization zonecontinuously, in steps, or with superposition of a concentrationgradient. In some embodiments, the copolymer is produced in a singlestage (i.e., does not include separate feeds having different monomercompositions so as to produce a multistage polymer particle such as acore/shell particle).

The emulsion polymerization can be performed with a variety ofauxiliaries, including water-soluble initiators and regulators. Examplesof water-soluble initiators for the emulsion polymerization are ammoniumsalts and alkali metal salts of peroxodisulfuric acid, e.g., sodiumperoxodisulfate, hydrogen peroxide or organic peroxides, e.g.,tert-butyl hydroperoxide. Reduction-oxidation (redox) initiator systemsare also suitable as initiators for the emulsion polymerization. Theredox initiator systems are composed of at least one, usually inorganic,reducing agent and one organic or inorganic oxidizing agent. Theoxidizing component comprises, for example, the initiators alreadyspecified above for the emulsion polymerization. The reducing componentsare, for example, alkali metal salts of sulfurous acid, such as sodiumsulfite, sodium hydrogen sulfite, alkali metal salts of disulfurous acidsuch as sodium disulfite, bisulfite addition compounds with aliphaticaldehydes and ketones, such as acetone bisulfite, or reducing agentssuch as hydroxymethanesulfinic acid and salts thereof, or ascorbic acid.The redox initiator systems can be used in the company of soluble metalcompounds whose metallic component is able to exist in a plurality ofvalence states. Typical redox initiator systems include, for example,ascorbic acid/iron(II) sulfate/sodium peroxodisulfate, tert-butylhydroperoxide/sodium disulfite, tert-butyl hydroperoxide/Nahydroxymethanesulfinate, or tert-butyl hydroperoxide/ascorbic acid. Theindividual components, the reducing component for example, can also bemixtures, an example being a mixture of the sodium salt ofhydroxymethanesulfinic acid with sodium disulfite. The stated compoundsare used usually in the form of aqueous solutions, with the lowerconcentration being determined by the amount of water that is acceptablein the dispersion, and the upper concentration by the solubility of therespective compound in water. The concentration can be 0.1% to 30%, 0.5%to 20%, or 1.0% to 10%, by weight, based on the solution. The amount ofthe initiators is generally 0.1% to 10% or 0.5% to 5% by weight, basedon the monomers to be polymerized. It is also possible for two or moredifferent initiators to be used in the emulsion polymerization. For theremoval of the residual monomers, an initiator can be added after theend of the emulsion polymerization.

In the polymerization it is possible to use molecular weight regulatorsor chain transfer agents, in amounts, for example, of 0 to 0.8 parts byweight, based on 100 parts by weight of the monomers to be polymerized,to reduce the molecular weight of the copolymer. Suitable examplesinclude compounds having a thiol group such as tert-butyl mercaptan,thioglycolic acid ethylacrylic esters, mercaptoethanol,mercaptopropyltrimethoxysilane, and tert-dodecyl mercaptan.Additionally, it is possible to use regulators without a thiol group,such as terpinolene. In some embodiments, the emulsion polymer isprepared in the presence of greater than 0% to 0.5% by weight, based onthe monomer amount, of at least one molecular weight regulator. In someembodiments, the emulsion polymer is prepared in the presence of lessthan less than 0.3% or less than 0.2% by weight (e.g., 0.10% to 0.15% byweight) of the molecular weight regulator.

Dispersants, such as surfactants, can also be added duringpolymerization to help maintain the dispersion of the monomers in theaqueous medium. For example, the polymerization can include less than 3%by weight or less than 1% by weight of surfactants. In some embodiments,the polymerization is substantially free of surfactants and can includeless than 0.05% or less than 0.01% by weight of one or more surfactants.

Anionic and nonionic surfactants can be used during polymerization.Suitable surfactants include ethoxylated C₈ to C₃₆ or C₁₂ to C₁₈ fattyalcohols having a degree of ethoxylation of 3 to 50 or of 4 to 30,ethoxylated mono-, di-, and tri-C₄ to C₁₂ or C₄ to C₉ alkylphenolshaving a degree of ethoxylation of 3 to 50, alkali metal salts ofdialkyl esters of sulfosuccinic acid, alkali metal salts and ammoniumsalts of C₈ to C₁₂ alkyl sulfates, alkali metal salts and ammonium saltsof C₁₂ to C₁₈ alkylsulfonic acids, and alkali metal salts and ammoniumsalts of C₉ to C₁₈ alkylarylsulfonic acids. Cationic emulsifiersinclude, for example, compounds having at least one amino group orammonium group and at least one C₈-C₂₂ alkyl group.

The coating compositions described herein further contain one or morederivatized polyamines The derivatized polyamine functions as a settingagent, and decreases the setting time of the coating compositions.

Polyamines are compounds which contain a plurality of primary aminegroups, secondary amine groups, or combinations thereof. Generally, thepolyamine contains at least three primary amine groups, secondary aminegroups, or combinations thereof. For example, the polyamine can containat least 5 primary and/or secondary amine groups, at least 10 primaryand/or secondary amine groups, at least 15 primary and/or secondaryamine groups, at least 20 primary and/or secondary amine groups, atleast 25 primary and/or secondary amine groups, at least 50 primaryand/or secondary amine groups, or more. The polyamines can optionallyfurther contain one or more tertiary amine groups.

The polyamine can be a polymer or copolymer derived from one or moremonomers containing an amine group. Suitable monomers of this typeinclude vinylamine, allylamine, and ethyleneimine. Other suitableamino-containing monomers include (meth)acrylate monomers containing oneor more primary and/or secondary amine groups, such as 2-aminoethylmethacrylate, 2-aminoethyl acrylate, 2-(tert-butylamino)ethyl acrylate,2-(tert-butylamino)ethyl methacrylate. In some embodiments, thepolyamine is an acrylic polymer derived from one or more monomerscomprising an amino group.

Derivatized polyamines as used herein are polyamines that areN-derivatized such that one or more amine nitrogens have beenderivatized (i.e., some number of the primary and/or secondary aminegroups within the polyamine have been covalently modified to replace oneor more hydrogen atoms in the primary and/or secondary amine groups witha non-hydrogen moiety). For example, in the case of polyaminescontaining one or more primary amine groups, derivatized polyamines caninclude polyamines where at least a portion of the primary amine groupshave been converted to either secondary or tertiary amine groups. In thecase of polyamines containing one or more secondary amine groups,derivatized polyamines can include polyamines where at least a portionof the secondary amine groups have been converted to tertiary amines.

Suitable derivatized polyamines are known in the art, and includepolyamines in which some number of the primary and/or secondary aminegroups have been covalently modified to replace one or more hydrogenatoms with a non-hydrogen moiety (R). In some embodiments, each R withinthe derivatized polyamine is individually selected from the groupconsisting of a C1-6 alkyl group, optionally substituted with one ormore hydroxyl groups; an acyl group (—COR₁), wherein R₁ is a C1-C6 alkylgroup or a C5-C7 aryl or heteroaryl group, optionally substituted withone or more hydroxyl groups; (—COOR₂), wherein R₂ is a C1-C6 alkyl groupor a C5-C7 aryl or heteroaryl group, optionally substituted with one ormore hydroxyl groups; (—SO₂R₃), wherein R₃ is a C1-C6 alkyl group or aC5-C7 aryl or heteroaryl group, optionally substituted with one or morehydroxyl groups, and a poly(alkylene oxide) group. The R groups presentwithin a derivatized polyamine can be selected such that the derivatizedpolyamine possesses a hydrophilicity which renders the derivatizedpolyamine compatible with the aqueous compositions described herein. Forexample, the R groups within the derivatized polyamine can be selectedsuch that the derivatized polyamine is water soluble or waterdispersible. In some embodiments, at least 50% of the derivatized aminegroups are alkoxylated amine groups.

In some embodiments, the derivatized polyamine includes alkoxylatedpolyamine groups. Suitable alkoxylated polyamines include alkoxylatedpolyamines derived from 2 to 8 carbon alkylene oxides. In certaininstances, the alkoxylated polyamine is derived from ethylene oxide,propylene oxide, butylene oxide, or combinations thereof. In particularembodiments, the alkoxylated polyamine is an alkoxylatedpolyalkyleneimine, an alkoxylated polyvinylamine, or a combinationthereof. Suitable alkoxylated polyvinylamines include those described inU.S. Pat. No. 7,268,199 to Andre, et al., which is incorporated hereinby reference for its teaching of alkoxylated polyvinylamines. Suitablealkoxylated polyalkyleneimines, as well as methods of making thereof,are also known in the art. See, for example, U.S. Pat. No. 7,736,525 toThankachan, et al., U.S. Pat. No. 6,811,601 to Borzyk, et al., and WO99/67352, all of which are incorporated herein by reference for theirteaching of alkoxylated polyalkyleneimines. Suitable alkoxylatedpolyamines also include, for example, those described in U.S. Pat. No.8,193,144 to Tanner, et al., which is incorporated herein by referencefor the alkoxylated polyamines described therein. In particularembodiments, the composition contains an ethoxylated polyethyleneimine,a propoxylated polyethyleneimine, a butoxylated polyethyleneimine, or acombination thereof.

In some embodiments, the derivatized polyamine includes an alkylatedpolyalkyleneimine (e.g., an alkylated polyethyleneimine or an alkylatedpolyvinylamine), a hydroxyalkylated polyalkyleneimine (e.g., ahydroxalkylated polyethyleneimine or a hydroxyalkylated polyvinylamine),an acylated polyalkyleneimine (e.g., an acylated polyethyleneimine or anacylated polyvinylamine), or a combination thereof.

Derivatized polyamines are generally incorporated into the compositionsin amounts less than 10% by weight, based on the dry weight of theanionically stabilized copolymer. The amount of derivatized polyaminepresent in the composition can be selected in view of the identity ofthe derivatized polyamine, the nature of the anionically stabilizedcopolymer present in the composition, and the desired setting time ofthe composition.

In some instances, the derivatized polyamine is present in an amountgreater than 0.05% by weight, greater than 0.1% by weight, greater than0.15% by weight, greater than 0.20% by weight, greater than 0.25% byweight, greater than 0.3% by weight, greater than 0.4% by weight,greater than 0.5% by weight, greater than 0.6% by weight, greater than0.7% by weight, greater than 0.8% by weight, greater than 0.9% byweight, greater than 1.0% by weight, greater than 1.25% by weight,greater than 1.5% by weight, greater than 2% by weight, or greater than2.5% by weight. In some instances, the derivatized polyamine is presentin an amount less than 8% by weight, less than 7.5% by weight, less than6% by weight, less than 5% by weight, less than 4.5% by weight, lessthan 4% by weight, less than 3.5% by weight, less than 3% by weight,less than 2.5% by weight, less than 2% by weight, less than 1.5% byweight, less than 1% by weight, or less than 0.5% by weight.

In some embodiments, the derivatized polyamine is present in thecomposition at between 0.1% by weight and 5% by weight, based on the dryweight of the anionically stabilized copolymer. In certain embodiments,the derivatized polyamine is present in the composition at between 0.5%by weight and 2.5% by weight, based on the dry weight of the anionicallystabilized copolymer.

Derivatized polyamines having a range of molecular weights and degreesof nitrogen-derivatization can be incorporated into the coatingcompositions. The setting time of the composition, as well as thephysical properties of the resultant coating, can be varied by selectionof the loading level, molecular weight, microstructure (e.g., degree ofbranching), and the degree of nitrogen-derivatization of the derivatizedpolyamine. The setting time of the composition, as well as the physicalproperties of the resultant coating, can also be influenced by ambientconditions during coating application and drying, including humidity andtemperature. In some embodiments, a particular derivatized polyamine isincorporated into the coating composition at a particular loading levelin view of ambient conditions, including humidity and temperature, toachieve a coating having a desired setting time, desired physicalproperties, or a combination thereof.

In some embodiments, the derivatized polyamine has an average molecularweight of greater than 500 Daltons, greater than 1,000 Daltons, greaterthan 2,500 Daltons, greater than 5,000 Daltons, greater than 10,000Daltons, greater than 15,000 Daltons, greater than 20,000 Daltons,greater than 25,000 Daltons, greater than 30,000 Daltons, greater than35,000 Daltons, greater than 40,000 Daltons, greater than 50,000Daltons, greater than 60,000 Daltons, greater than 70,000 Daltons,greater than 80,000 Daltons, greater than 90,000 Daltons, or greaterthan 100,000 Daltons. The derivatized polyamine can have an averagemolecular weight of less than 5,000,000 Daltons, less than 2,500,000,less than 1,000,000, less than 750,000 Daltons, 550,000 Daltons, lessthan 500,000 Daltons, less than 450,000 Daltons, less than 400,000Daltons, less than 350,000 Daltons, less than 300,000 Daltons, less than350,000 Daltons, less than 300,000 Daltons, less than 250,000 Daltons,less than 200,000 Daltons, less than 175,000 Daltons, less than 150,000Daltons, less than 125,000 Daltons, or less than 100,000 Daltons. Incertain embodiments, the derivatized polyamine has an average molecularweight of between 5,000 and 5,000,000 Daltons, of between 5,000 Daltonsand 500,000 Daltons, or between 40,000 and 150,000 Daltons.

Generally, the derivatized polyamine will have a degree ofnitrogen-derivatization, defined as the percentage of availablenitrogens within the polyamine that have been covalently modified toreplace one or more hydrogen atoms with a non-hydrogen moiety, of atleast 5%. In certain embodiments, the derivatized polyamine has a degreeof nitrogen-derivization of at least 10%, at least 15%, at least 20%, atleast 25%, at least 30%, at least 35%, at least 40%, at least 45%, atleast 50%, at least 55%, at least 60%, at least 65%, at least 70%, atleast 75%, at least 80%, at least 85%, or at least 90%. In certainembodiments, the derivatized polyamine has a degree ofnitrogen-derivatization of less than 99%, less than 98%, less than 97%,less than 95%, less than 90%, less than 85%, less than 80%, or less than75%.

In some embodiments, the derivatized polyamine has a degree ofnitrogen-derivatization between 5% and 100%. In certain embodiments, thederivatized polyamine has a degree of nitrogen-derivatization between50% and 95% or between 70% and 90%. In embodiments where the derivatizedpolyamine is an alkoxylated polyamine, the degree ofnitrogen-derivatization can be referred to as the degree of nitrogenalkoxylation, defined as the percentage of available nitrogens withinthe polyamine that have been converted to a corresponding hydroxyalkylgroup.

The quick-setting coating compositions described herein also contain avolatile base. Volatile bases are basic substances that are soluble inwater, remain in the aqueous coating composition under normal storageconditions, and evaporate from the aqueous coating composition undersuitable drying conditions.

Generally, one or more volatile bases are incorporated in thecomposition in an effective amount to maintain the pH of the coatingcomposition in the range of from 7.5 to 12.5 or in the range from 9 to11. In some embodiments, one or more volatile bases are incorporated inthe composition at between 0.1% by weight and 5.0% by weight. In certainembodiments, one or more volatile bases are incorporated in thecomposition at between 0.5% by weight and 2.5% by weight.

Suitable volatile bases can be selected on the basis of several factors,including their basicity and volatility. Exemplary volatile basesinclude, but are not limited to, ammonia, lower alkylamines such asdimethylamine, triethylamine, and diethylamine, ethanolamine,diethanolamine, triethanolamine, morpholine, aminopropanol,2-amino-2-methyl-1-propanol, 2-dimethylaminoethanol, and combinationsthereof. In certain embodiments, the volatile base is ammonia. In somecases, ammonia is the sole volatile base present in the coatingcomposition. Alternatively, ammonia can be incorporated in admixturewith other volatile bases, non-volatile bases, such as alkali metalhydroxides, or combinations thereof.

In some embodiments, the composition can further contain an additionalpolymer, which may or may not be anionically stabilized. The additionalpolymer can be, for example, a polymer or copolymer derived from themonomers described herein.

When present, the additional polymer is typically present in an amountgreater than 0% by weight to 15% by weight, based on the weight of theanionically stabilized copolymer. In some instances, the additionalpolymer is present in an amount less than 10% by weight, less than 7.5%by weight, less than 5% by weight, less than 2.5% by weight, less than2% by weight, less than 1.5% by weight, or less than 1% by weight, basedon the weight of the anionically stabilized copolymer. When present, theadditional polymer is generally present in an amount greater than 0.05%by weight, greater than 0.1% by weight, greater than 0.25% by weight,greater than 0.5% by weight, greater than 0.75% by weight, greater than1.0% by weight, greater than 1.5% by weight, or greater than 2.5% byweight, based on the weight of the anionically stabilized copolymer. Insome embodiments, the additional copolymer is present in the compositionat between 0.1% by weight and 10% by weight, based on the weight of theanionically stabilized copolymer.

In some embodiments, the additional polymer can include a polymer havinga T_(g) of between −70° C. and 60° C. In some cases, the additionalpolymer has a measured T_(g) of greater than −70° C. (e.g., greater than−60° C., greater than −50° C., greater than −40° C., greater than −30°C., greater than −20° C., greater than −10° C., greater than 0° C.,greater than 10° C., greater than 20° C., or greater than 30° C.). Incertain instances, the additional polymer has a measured T_(g) of lessthan 60° C. (e.g., less than 50° C., less than 40° C., less than 30° C.,less than 20° C., less than 10° C., less than 0° C., less than −10° C.,less than −20° C., less than -30° C., less than −40° C., or less than−50° C.). In some instances, the additional polymer has a measured T_(g)of between −70° C. and 50° C. In certain instances, the additionalpolymer has a T_(g) of between −20° C. and 50° C. In some embodiments,the additional copolymer has a T_(g) of greater than 60° C. or less than−70° C.

In some embodiments, the additional polymer has a T_(g) that is greaterthan the T_(g) of the anionically stabilized copolymer. For example, theadditional polymer can have a measured T_(g) that is 5° C. or greater,10° C. or greater, 15° C. or greater, 20° C. or greater, 25° C. orgreater, 30° C. or greater, 35° C. or greater, 40° C. or greater, 45° C.or greater, or 50° C. or greater than the measured T_(g) of theanionically stabilized copolymer.

The aqueous coating compositions can further include one or moreadditives, including pigments, fillers, dispersants, coalescents, pHmodifying agents, plasticizers, defoamers, surfactants, thickeners,biocides, co-solvents, and combinations thereof. The choice of additivesin the composition will be influenced by a number of factors, includingthe nature of the acrylic polymer dispersion and the intended use of thecoating composition.

Examples of suitable pigments include metal oxides, such as titaniumdioxide, zinc oxide, iron oxide, or combinations thereof. In certainembodiments, the composition includes a titanium dioxide pigment.Examples of commercially titanium dioxide pigments are KRONOS® 2101,KRONOS® 2310, available from Kronos WorldWide, Inc. (Cranbury, N.J.),TI-PURE® R-900, available from DuPont (Wilmington, Del.), or TIONA® AT1commercially available from Millenium Inorganic Chemicals. Titaniumdioxide is also available in concentrated dispersion form. An example ofa titanium dioxide dispersion is KRONOS® 4311, also available fromKronos WorldWide, Inc.

Examples of suitable fillers include calcium carbonate, nephelinesyenite, (25% nepheline, 55% sodium feldspar, and 20% potassiumfeldspar), feldspar (an aluminosilicate), diatomaceous earth, calcineddiatomaceous earth, talc (hydrated magnesium silicate),aluminosilicates, silica (silicon dioxide), alumina (aluminum oxide),clay, (hydrated aluminum silicate), kaolin (kaolinite, hydrated aluminumsilicate), mica (hydrous aluminum potassium silicate), pyrophyllite(aluminum silicate hydroxide), perlite, baryte (barium sulfate),Wollastonite (calcium metasilicate), and combinations thereof. Incertain embodiments, the composition comprises a calcium carbonatefiller.

Examples of suitable dispersants are polyacid dispersants andhydrophobic copolymer dispersants. Polyacid dispersants are typicallypolycarboxylic acids, such as polyacrylic acid or polymethacrylic acid,which are partially or completely in the form of their ammonium, alkalimetal, alkaline earth metal, ammonium, or lower alkyl quaternaryammonium salts. Hydrophobic copolymer dispersants include copolymers ofacrylic acid, methacrylic acid, or maleic acid with hydrophobicmonomers. In certain embodiments, the composition includes a polyacrylicacid-type dispersing agent, such as Pigment Disperser N, commerciallyavailable from BASF SE.

Suitable coalescents, which aid in film formation during drying, includeethylene glycol monomethyl ether, ethylene glycol monobutyl ether,ethylene glycol monoethyl ether acetate, ethylene glycol monobutyl etheracetate, diethylene glycol monobutyl ether, diethylene glycol monoethylether acetate, dipropylene glycol monomethyl ether,2,2,4-trimethyl-1,3-pentanediol monoisobutyrate, and combinationsthereof.

Examples of suitable thickening agents include hydrophobically modifiedethylene oxide urethane (HEUR) polymers, hydrophobically modified alkalisoluble emulsion (HASE) polymers, hydrophobically modified hydroxyethylcelluloses (HMHECs), hydrophobically modified polyacrylamide, andcombinations thereof. HEUR polymers are linear reaction products ofdiisocyanates with polyethylene oxide end-capped with hydrophobichydrocarbon groups. HASE polymers are homopolymers of (meth)acrylicacid, or copolymers of (meth)acrylic acid, (meth)acrylate esters, ormaleic acid modified with hydrophobic vinyl monomers. HMHECs includehydroxyethyl cellulose modified with hydrophobic alkyl chains.Hydrophobically modified polyacrylamides include copolymers ofacrylamide with acrylamide modified with hydrophobic alkyl chains(N-alkyl acrylamide). In certain embodiments, the coating compositionincludes a hydrophobically modified hydroxyethyl cellulose thickener.

Examples of suitable pH modifying agents include amino alcohols,monoethanolamine (MEA), diethanolamine (DEA), 2-(2-aminoethoxy)ethanol,diisopropanolamine (DIPA), 1-amino-2-propanol (AMP), ammonia, andcombinations thereof.

Defoamers serve to minimize frothing during mixing and/or application ofthe coating composition. Suitable defoamers include silicone oildefoamers, such as polysiloxanes, polydimethylsiloxanes, polyethermodified polysiloxanes, and combinations thereof. Exemplarysilicone-based defoamers include BYK®-035, available from BYK USA Inc.(Wallingford, Conn.), the TEGO® series of defoamers, available fromEvonik Industries (Hopewell, Va.), and the DREWPLUS® series ofdefoamers, available from Ashland Inc. (Covington, Ky.).

Suitable surfactants include nonionic surfactants and anionicsurfactants. Examples of nonionic surfactants are alkylphenoxypolyethoxyethanols having alkyl groups of about 7 to about 18 carbonatoms, and having from about 6 to about 60 oxyethylene units; ethyleneoxide derivatives of long chain carboxylic acids; analogous ethyleneoxide condensates of long chain alcohols, and combinations thereof.Exemplary anionic surfactants include ammonium, alkali metal, alkalineearth metal, and lower alkyl quaternary ammonium salts ofsulfosuccinates, higher fatty alcohol sulfates, aryl sulfonates, alkylsulfonates, alkylaryl sulfonates, and combinations thereof. In certainembodiments, the composition comprises a nonionic alkylpolyethyleneglycol surfactant, such as LUTENSOL® TDA 8 or LUTENSOL® AT-18,commercially available from BASF SE. In certain embodiments, thecomposition comprises an anionic alkyl ether sulfate surfactant, such asDISPONIL® FES 77, commercially available from BASF SE. In certainembodiments, the composition comprises an anionic diphenyl oxidedisulfonate surfactant, such as CALFAX® DB-45, commercially availablefrom Pilot Chemical.

Suitable biocides can be incorporated to inhibit the growth of bacteriaand other microbes in the coating composition during storage. Exemplarybiocides include 2-[(hydroxymethyl)amino]ethanol, 2-[(hydroxymethyl)amino]2-methyl-1-propanol, o-phenylphenol, sodium salt,1,2-benzisothiazolin-3-one, 2-methyl-4-isothiazolin-3-one (MIT),5-chloro2-methyland-4-isothiazolin-3-one (CIT),2-octyl-4-isothiazolin-3-one (OTT),4,5-dichloro-2-n-octyl-3-isothiazolone, as well as acceptable salts andcombinations thereof. Suitable biocides also include mildewcides thatinhibit the growth mildew or its spores in the coating. Examples ofmildeWcides include 2-(thiocyanomethylthio)benzothiazole,3-iodo-2-propynyl butyl carbamate, 2,4,5,6-tetrachloroisophthalonitrile,2-(4-thiazolyl)benzimidazole, 2-N-octyl4-isothiazolin-3-one,diiodomethyl p-tolyl sulfone, as well as acceptable salts andcombinations thereof. In certain embodiments, the coating compositioncontains 1,2-benzisothiazolin-3-one or a salt thereof. Biocides of thistype include PROXEL® BD20, commercially available from Arch Chemicals,Inc (Atlanta, Ga.).

Exemplary co-solvents and plasticizers include ethylene glycol,propylene glycol, diethylene glycol, and combinations thereof.

Other suitable additives that can optionally be incorporated into thecomposition include rheology modifiers, wetting and spreading agents,leveling agents, conductivity additives, adhesion promoters,anti-blocking agents, anti-cratering agents and anti-crawling agents,anti-freezing agents, corrosion inhibitors, anti-static agents, flameretardants and intumescent additives, dyes, optical brighteners andfluorescent additives, UV absorbers and light stabilizers, chelatingagents, cleanability additives, crosslinking agents, flatting agents,flocculants, humectants, insecticides, lubricants, odorants, oils, waxesand slip aids, soil repellants, stain resisting agents, and combinationsthereof.

The coating compositions described above can be provided as aqueousdispersions having a solids content of from 50-85% or from 60-75%. Insome cases, the coating compositions described herein can be provided aspowder formulations. Powder formulations of this type include ananionically stabilized copolymer, a derivatized polyamine, andoptionally one or more additives (e.g., pigments, fillers, and/orspray-drying aids) as described above. The powder formulations can bereconstituted prior to use, for example, by addition of water, one ormore volatile bases, and optionally one or more co-solvents, to providethe aqueous coating compositions described above.

Also provided are coatings formed from the coating compositionsdescribed herein, as well as methods of forming these coatings.Generally, coatings are formed by applying a coating compositiondescribed herein to a surface, and allowing the coating to dry to form acoating. The resultant dry coatings typically comprise, at minimum, ananionically stabilized polymer and a derivatized polyamine The drycoatings can further comprise one or more additives (e.g., pigmentsand/or fillers) as described above.

Coating compositions can be applied to a surface by any suitable coatingtechnique, including spraying, rolling, brushing, or spreading. Coatingcompositions can be applied in a single coat, or in multiple sequentialcoats (e.g., in two coats or in three coats) as required for aparticular application. Generally, the coating composition is allowed todry under ambient conditions. However, in certain embodiments, thecoating composition can be dried, for example, by heating and/or bycirculating air over the coating.

The coating can be co-applied with a setting accelerator to decrease thesetting time of the coating on a surface. Suitable setting acceleratorsinclude compounds, such as acids, which consume the volatile base anddecrease coating setting time. For example, the setting accelerator canbe a dilute acid, such as acetic acid or citric acid. Settingaccelerators can be applied to a surface prior to coating application,applied simultaneously with the coating composition, or applied to thecoating after it has been applied to a surface but prior to drying.

Coating thickness can vary depending upon the application of thecoating. For example, the coating can have a dry thickness of at least10 mils (e.g., at least 15 mils, at least 20 mils, at least 25 mils, atleast 30 mils, or at least 40 mils). In some instances, the coating hasa dry thickness of less than 100 mils (e.g., less than 90 mils, lessthan 80 mils, less than 75 mils, less than 60 mils, less than 50 mils,less than 40 mils, less than 35 mils, or less than 30 mils). In someembodiments, the coating has a dry thickness of between 10 mils and 100mils. In certain embodiments, the coating has a dry thickness of between10 mils and 40 mils.

The elongation at break of the coatings described herein can be measuredaccording to ASTM D-2370. Generally, the coatings display an elongationat break after a drying period of at least 14 days, as measuredaccording to ASTM D-2370 of at least 90% (e.g., at least 95%, at least100%, at least 110%, at least 120%, at least 130%, at least 140%, atleast 150%, at least 160%, at least 170%, at least 180%, at least 190%,or at least 200%). In some embodiments, the coatings display anelongation at break after 1,000 of accelerated weathering, as measuredaccording to ASTM D-2370 of at least 90% (e.g., at least 95%, at least100%, at least 110%, at least 120%, at least 130%, at least 140%, atleast 150%, at least 160%, at least 170%, at least 180%, at least 190%,or at least 200%).

The tensile strength of the coatings described herein can be measuredaccording to ASTM D-2370. Generally, the coatings display tensile aftera drying period of at least 14 days, as measured according to ASTMD-2370 of at least 140 psi (e.g., at least 150 psi, at least 160 psi, atleast 170 psi, at least 180 psi, at least 190 psi, at least 200 psi, atleast 210 psi, at least 220 psi, or at least 225 psi). In someembodiments, the coatings display tensile strength after 1,000 ofaccelerated weathering, as measured according to ASTM D-2370 of at least140 psi (e.g., at least 150 psi, at least 160 psi, at least 170 psi, atleast 180 psi, at least 190 psi, at least 200 psi, at least 210 psi, atleast 220 psi, or at least 225 psi)

The coating compositions can be applied to a variety of surfacesincluding, but not limited to metal, asphalt, concrete, stone, ceramic,wood, plastic, polyurethane foam, glass, and combinations thereof.

The coating compositions can be applied to interior or exteriorsurfaces. In certain embodiments, the surface is an architecturalsurface, such as a roof, wall, floor, or combination thereof. Thearchitectural surface can be located above ground, below ground, orcombinations thereof.

In some cases, the coating is applied to a surface to form a batheragainst moisture. For example, coatings can be applied to a roof or wallto prevent or seal a water leak. The coating can be applied to afoundation, wall, or roof as a water proofing composition to preventwater penetration (e.g., to form an elastomeric weatherproofingmembrane). In some instances, the coating is applied to a surface incombination with a conventional weatherproofing membrane. The coatingcan also be applied as part of an exterior insulating and finishingsystem (EIFS).

In certain embodiments, the coating is applied to a surface to reflectsolar radiation. In these cases, the coating will generally contain oneor more pigments that reflect solar energy, such as titanium dioxide. Byreflecting the sun's heat, the coating can help to cool a surface. Inthe case of coatings applied to architectural surfaces such as roofs,the roof coating can help to reduce a building's interior temperaturesand cooling costs.

In some embodiments, the coating is applied to a road surface as atraffic paint. In these embodiments, the road surface can be, forexample, asphalt or concrete. In some cases when the coating is appliedas a traffic paint, the coating contains a filler such as a reflectivefiller.

In certain embodiments, the coating is an elastomeric roof coating. Incertain embodiments, the coating will generally satisfy the requirementsof ASTM D6083-05, entitled “Standard Specification for Liquid AppliedAcrylic Coating Used in Roofing”. In particular embodiments, the coatinghas a tensile strength of greater than 200 psi, and an elongation atbreak of greater than 100%, according to ASTM D-2370, after 1,000 hoursof accelerated weathering.

Also provided are methods of decreasing the setting time of conventionalacrylic elastomeric roof coating compositions comprising adding aderivatized polyamine, such as an alkoxylated polyamine, to theelastomeric roof coating composition. In these embodiments, thederivatized polyamine is generally added in an amount as describedherein, for example, between greater than 0% by weight and 10% byweight, based on the weight of the elastomeric components in the roofcoating composition. These compositions can then be applied to asurface, and allowed to dry ask described above.

Derivatized polyamines can also be incorporated as setting agents inother types of compositions which contain anionically stabilizedcopolymers. In particular, derivatized polyamines may be utilized todecrease the setting time of other compositions where fast settingand/or rain resistance are desirable. For example, derivatizedpolyamines can be added to conventional adhesives (e.g., constructionadhesives), grouts, caulks, sealants, and exterior insulating andfinishing systems (EIFS) to decrease setting time.

By way of non-limiting illustration, examples of certain embodiments ofthe present disclosure are given below.

EXAMPLES Example 1 Compositions Containing a Polyethyleneimine SettingAgent

Elastomeric coatings containing an anionically stabilized acrylic-basedcopolymer (T_(g)−32° C.) and two different polyethyleneimines (PEI-1,MW=1,300 Daltons; PEI-2, MW=2,000 Daltons) were prepared as describedbelow.

For a 600 g coating composition, the following ingredients were mixed:

37 g water, 2.4 g Pigment Disperser N (BASF), 2.0 g propylene glycol,2.4 g BYK 035 defoamer (BYK), 1.0 g Lutensol TDA 8 (BASF), 60.7 g Kronos2310 (Kronos, Inc.), 43.0 g OMYACARB UFT-FL (Omya), 32.2 g ATOMITE(Imerys), 118.4 DURAMITE (Imerys), and 1.2 PROXEL DB20 biocide (ArchChem.) were mixed until homogeneous.

Then the following materials were subsequently added: 230 g aqueouspolymer emulsion, 46 g water, about 2 g 29% ammonia, or more to get topH 10, the appropriate amount of polyethyleneimine or other settingagent, 5.0 g BYK 035 defoamer (BYK), and finally a pre-mixed slurry of2.5 g NATROSOL 250 MXR (Ashland) in 100 g propylene glycol.

Simulated Rain Resistance of the Coatings

The formulations were applied as a 30 mil thick coating on black lanettapaper using a PGT Co. #2 draw down well Immediately after the coating isdrawn down, a timer set for 20 minutes was started. As the end of 20minutes approaches, the coated panel is placed on a stand that holds itat a 45° angle. A burette is setup directly above the panel. The tip ofthe burette is set at a distance of 10 inches from the panel surface.After a drying time of 20 minutes, DI water is dripped onto the coatedpanel. A total of 5 ml of DI water is dripped onto the panel overroughly 1 minute. The coating is tested at 20 minute intervals for up totwo hours. At the end of two hours, the integrity of the coating at eachtime interval is evaluated visually on a scale from 0 to 100%. Zeropercent would indicate no resistance to the water while one hundredpercent indicates no marring of the coating's surface as well as norunoff of the coating. A set time is then established for the samplebased upon a rating of 100%.

Measurement of Film Tensile Strength and Film Elongation at Break

After a drying period of fourteen days, the film tensile strength andfilm elongation at break were measured according to ASTM D-6083.

TABLE 1 Performance of Compositions Containing a PolyethyleneimineSetting Agent Film Film Film Tensile Elongation appearance BinderStrength at Break 20 Minutes 40 Minutes after System (psi) (%) DryingTime Drying Time weathering^((a)) Acrylic 145 200 Severe Severe Whitedamage/wash- damage/wash- off off Acrylic + 208 119 Severe Severe Severe1% PEI-1 damage/wash- damage/wash- yellowing off off Acrylic + 216 88Little No Severe 2% PEI-1 damage/no damage/no yellowing wash-offwash-off Acrylic + 224 116 Severe Severe Severe 1% PEI-2 damage/wash-damage/wash- yellowing off off Acrylic + 260 74 Almost no No Severe 2%PEI-2 damage/no damage/no yellowing wash-off wash-off PEI-1: MW = 1,300Daltons; PEI-2: MW = 2,000 Daltons ^((a))After 1,000 h acceleratedweathering.

Results

The film tensile strength, elongation at break, and simulated rainresistance of coatings formed from coating compositions containing ananionically stabilized acrylic-based copolymer (T_(g)=−32° C.) and twodifferent polyethyleneimines (PEI-1, MW=1,300 Daltons; PEI-2, MW=2,000Daltons) are shown in Table 1.

As shown in Table 1, the composition containing an anionicallystabilized acrylic-based copolymer and no PEI exhibited no resistance towash-off after 40 minutes. The addition of PEI improved the damage- andwash-off resistance of the coatings, with compositions containing 2% PEIexhibiting no damage and no wash-off after 40 minutes. However, theaddition of PEI significantly reduced film elongation at break, withcompositions containing 2% PEI exhibiting film elongation at breakvalues of less than 100%. Moreover, all compositions containing PEIdisplayed severe yellowing after accelerated weathering.

Example 2 Compositions Containing an Alkoxylated Polyethyleneimine(APEI) Setting Agent

Elastomeric coatings containing one of two different anionicallystabilized acrylic-based copolymers (Acrylic-1: T_(g)=−32° C.;Acrylic-2: T_(g)=−28° C.) and an ethoxylated polyethyleneimine wereprepared as described below.

For a 600 g coating composition, the following ingredients were mixed:

37 g water, 2.4 g Pigment Disperser N (BASF), 2.0 g propylene glycol,2.4 g BYK 035 defoamer (BYK), 1.0 g Lutensol TDA 8 (BASF), 60.7 g Kronos2310 (Kronos, Inc.), 43.0 g OMYACARB UFT-FL (Omya), 32.2 g ATOMITE(Imerys), 118.4 DURAMITE (Imerys), and 1.2 PROXEL DB20 biocide (ArchChem.) were mixed until homogeneous.

Then the following materials were subsequently added: 230 g aqueouspolymer emulsion, 46 g water, about 2 g 29% ammonia, or more to get topH 10, the appropriate amount of polyethyleneimine or other settingagent, 5.0 g BYK 035 defoamer (BYK), and finally a pre-mixed slurry of2.5 g NATROSOL 250 MXR (Ashland) in 100 g propylene glycol.

The film tensile strength, elongation at break, and simulated rainresistance of coatings formed from these coating compositions weremeasured, as described above in Example 1.

TABLE 2 Performance of Compositions Containing an AlkoxylatedPolyethyleneimine Setting Agent Film Film Film Tensile Elongationappearance Binder Strength at Break 20 Minutes 40 Minutes after System(psi) (%) Drying Time Drying Time weathering^((a)) Acrylic-1 151 179Severe Severe White damage/wash- damage/wash- off off Acrylic-1 + 148201 Severe Partial Very slightly 0.5% APEI damage/wash- damage/someyellow off wash-off Acrylic-1 + 154 228 Little No damage/no Veryslightly 1.0% APEI damage/no wash-off yellow wash-off Acrylic-2 213 208Severe Severe White damage/wash- damage/wash- off off Acrylic-2 + 204235 Partial No damage/no Very slightly 0.5% APEI damage/some wash-offyellow wash-off Acrylic-2 + 187 259 No damage/no No damage/no Veryslightly 1.0% APEI wash-off wash-off yellow Acrylic-1: T_(g) = −32° C.;Acrylic-2: T_(g) = −28° C.; APEI: MW = 110,000 Daltons, Degree ofEthoxylation = 80% ^((a))After 1,000 h accelerated weathering.

Results

The film tensile strength, elongation at break, and simulated rainresistance of coatings formed from coating compositions containing oneof two different anionically stabilized acrylic-based copolymer(Acrylic-1: T_(g)=−32° C.; Acrylic-2: T_(g)=−28° C.) and an ethoxylatedpolyethyleneimine (APEI) are shown in Table 2.

As shown in Table 2, compositions containing an anionically stabilizedacrylic-based copolymer and no APEI exhibited no resistance to wash-offafter 40 minutes. The addition of APEI improved the damage- and wash-offresistance of the coatings, with compositions containing 1% APEIexhibiting no damage and no wash-off after 40 minutes. In addition, theaddition of APEI enhanced the film elongation at break, withcompositions containing 1% APEI exhibiting greater than 200% elongationat break. Moreover, all compositions containing APEI did not exhibityellowing after accelerated weathering.

The compositions and methods of the appended claims are not limited inscope by the specific compositions and methods described herein, whichare intended as illustrations of a few aspects of the claims and anycompositions and methods that are functionally equivalent are intendedto fall within the scope of the claims. Various modifications of thecompositions and methods in addition to those shown and described hereinare intended to fall within the scope of the appended claims. Further,while only certain representative compositions and method stepsdisclosed herein are specifically described, other combinations of thecompositions and method steps also are intended to fall within the scopeof the appended claims, even if not specifically recited. Thus, acombination of steps, elements, components, or constituents may beexplicitly mentioned herein or less, however, other combinations ofsteps, elements, components, and constituents are included, even thoughnot explicitly stated. The term “comprising” and variations thereof asused herein is used synonymously with the term “including” andvariations thereof and are open, non-limiting terms. Although the terms“comprising” and “including” have been used herein to describe variousembodiments, the terms “consisting essentially of” and “consisting of”can be used in place of “comprising” and “including” to provide for morespecific embodiments of the invention and are also disclosed. Other thanin the examples, or where otherwise noted, all numbers expressingquantities of ingredients, reaction conditions, and so forth used in thespecification and claims are to be understood at the very least, and notas an attempt to limit the application of the doctrine of equivalents tothe scope of the claims, to be construed in light of the number ofsignificant digits and ordinary rounding approaches.

What is claimed is:
 1. An aqueous composition comprising: (a) ananionically stabilized copolymer derived from greater than 65% by weightof one or more (meth)acrylate monomers and has a Tg of between −50° C.and 0° C., wherein the anionically stabilized copolymer comprises (i)10-15% by weight methyl methacrylate; (ii) 50-70% by weight butylacrylate; (iii) 15-30% by weight 2-ethylhexylacrylate; (iv) greater than0 to 5% by weight carboxylic acid-containing monomers; (v) 0-5% byweight acrylamide; and (vi) 0-5% by weight acetoacetoxy monomers,wherein the anionically stabilized copolymer does not include aphosphorus-containing monomer; (b) a derivatized polyalkylene imine oran alkoxylated polyvinylamine in an amount of from greater than 0% to 5%by weight, based on the dry weight of the anionically stabilizedpolymer; and (c) a volatile base; wherein the derivatized polyalkyleneimine or alkoxylated polyvinylamine has a degree ofnitrogen-derivatization of at least 40%.
 2. The composition of claim 1,wherein the derivatized polyalkylene imine or alkoxylated polyvinylaminehas a degree of nitrogen-derivatization between 70% and 90%.
 3. Thecomposition of claim 1, wherein the derivatized polyalkylene imine oralkoxylated polyvinylamine comprises alkoxylated polyethyleneimine(PEI).
 4. The composition of claim 1, wherein the composition includesalkoxylated polyvinylamine.
 5. The composition of claim 1, wherein thederivatized polyalkylene imine or alkoxylated polyvinylamine is presentin the composition at between 0.1% by weight and 5% by weight, based onthe dry weight of the anionically stabilized copolymer.
 6. Thecomposition of claim 1, wherein the anionically stabilized copolymerincludes an acrylic-based copolymer, wherein the acrylic-based copolymeris derived from greater than 90% by weight of one or more (meth)acrylatemonomers.
 7. The composition of claim 6, wherein the one or more(meth)acrylate monomers are selected from the group consisting of methylmethacrylate, butyl acrylate, 2-ethylhexylacrylate, and combinationsthereof.
 8. The composition of claim 1, wherein the anionicallystabilized copolymer is derived from greater than 0% by weight to 5% byweight of one or more carboxylic acid-containing monomers.
 9. Thecomposition of claim 1, wherein the anionically stabilized copolymer isderived from greater than 0% by weight to 35% by weight of one or moreadditional ethylenically-unsaturated monomers, wherein the one or moreadditional ethylenically-unsaturated monomers include a vinyl aromaticmonomer.
 10. A method of producing a coating on a surface comprising (a)applying to the surface an aqueous coating composition defined by claim1; and (b) allowing the composition to dry to produce the coating,wherein the surface is an architectural surface or a roof.
 11. Themethod of claim 10, further comprising applying a setting accelerator.12. The composition of claim 1, wherein the derivatized polyalkyleneimine or an alkoxylated polyvinylamine is present in an amount of from0.05% to 5% by weight, based on the dry weight of the anionicallystabilized polymer.
 13. The composition of claim 1, wherein thecomposition has a tensile strength of greater than 200 psi and anelongation at break of greater than 100% after a drying period of 14days at room temperature, according to ASTM D-2370.
 14. An aqueouscomposition comprising: (a) an anionically stabilized copolymer derivedfrom (i) 55-75% by weight butyl acrylate; (ii) 0-25% by weight2-ethylhexylacrylate; (iii) greater than 0% to 35% by weight of one ormore additional ethylenically-unsaturated monomers; (iv) greater than 0to 5% by weight carboxylic acid-containing monomers; (v) 0-5% by weightacrylamide; and (vi) 0-5% by weight acetoacetoxy monomers and has a Tgof between −50° C. and −10° C., wherein the anionically stabilizedcopolymer does not include a phosphorus-containing monomer; (b) aderivatized polyamine in an amount of from greater than 0% to 5% byweight, based on the dry weight of the anionically stabilized polymer,wherein the derivatized polyamine is selected from a derivatizedpolyalkylene imine or an alkoxylated polyvinylamine; and (c) a volatilebase; wherein the derivatized polyamine has a degree ofnitrogen-derivatization of at least 40%.
 15. The composition of claim 1,wherein the anionically stabilized copolymer has a Tg of from −50° C. toless than −10° C.
 16. An aqueous composition comprising: (a) ananionically stabilized copolymer derived from greater than 65% by weightof one or more (meth)acrylate monomers and has a Tg of between −50° C.and 0° C., wherein the anionically stabilized copolymer comprises (i)55-75% by weight butyl acrylate; (ii) 0-25% by weight2-ethylhexylacrylate; (iii) greater than 0% to 35% by weight of one ormore additional ethylenically-unsaturated monomers; (iv) greater than 0to 5% by weight carboxylic acid-containing monomers; (v) 0-5% by weightacrylamide; and (vi) 0-5% by weight acetoacetoxy monomers, wherein theanionically stabilized copolymer and does not include aphosphorus-containing monomer; (b) a derivatized polyalkylene imine oran alkoxylated polyvinylamine in an amount of from greater than 0% to 5%by weight, based on the dry weight of the anionically stabilizedpolymer; and (c) a volatile base; wherein the derivatized polyalkyleneimine or alkoxylated polyvinylamine has a degree ofnitrogen-derivatization of at least 40%.